Garment mask for filtering breathable particles

ABSTRACT

A garment formed of a fabric that permits passage of inhaled and exhaled breath therethrough, comprising a portion of the garment optionally configurable between a first mode wherein the portion is folded away from the mouth and nose of a wearer of the garment and a second mode wherein the portion is disposed over the mouth and nose of a wearer of the garment, and an element of a medical filtration material disposed within the portion such that the element is positioned in the pathway of the inhaled and exhaled breath when the garment is in the second mode.

TECHNICAL FIELD

The present invention relates to an apparatus for filtering particles from air to be breathed or exhaled or both; more particularly, to masks for the protection of wearers, including but not limited to health workers, first responders, construction workers and athletes in in addition to ordinary people, from inhaling bacteria and/or viruses; as well as airborne irritants and most particularly to a garment, exemplarily a turtleneck-type, containing a mask material element concealed within a garment portion that is deployable over a wearer's mouth and nose.

BACKGROUND OF THE INVENTION

It is well known in the filtration and health arts to provide so-called disposable or single-use surgical and/or dust masks in the form of a pouch that covers a wearer's mouth and nose and semi-seals against the surrounding skin to condition the air being inhaled and exhaled by the wearer. Such masks typically are held in place during use by one or more straps, that may be elastic, that loop over the ears of the wearer or tie behind a user's head. If worn properly, such a mask is meant to help block large-particle droplets, splashes, sprays, splatter or dust that may contain bacteria, viruses and dust from reaching a wearer's mouth and nose during inhalation. Surgical masks may also help reduce exposure of a wearer's saliva and exhaled respiratory secretions to others.

The filtration material typically is a special paper and/or fabric formed to arrest and retain a certain size or class of airborne particles or droplets present in the inhaled and/or exhaled air of the wearer.

Surgical masks are regulated under 21 CFR 979.4040. A well-known filter material for such a mask is designated N95 by the National Institute for Occupational Safety and Health (NIOSH), a part of the United States Centers for Disease Control and Prevention (CDC). A surgical N95 mask is certified as an N95 respirator to remove at least 95% of a challenge aerosol under specific test conditions. The “N” signifies that the material is not resistant to oil. Other common mask materials are designated, e.g., PM2.5 and N99.

In times of public outbreak of airborne organisms, e.g., coronavirus (CORVID-19), it may become desirable for members of the general public to have respiratory protection, either from persons already infected with the disease or to prevent infecting others with the disease. Wearers of such commercial masks are obvious and in some cases are embarrassed to wear them. In other instances, a person may unexpectedly be in need of such protection on short notice or in circumstances that are transient, which require such user to be in close proximity with other people (e.g., a concert or during airline or bus travel or while jogging or riding a bike, as well as while working out in a gym or shopping).

As helpful as it may be to wear such masks, many people neglect to carry a mask with them when they leave the house or engage in an activity because they are an added accessory. Many people also resist using these masks because they look like hospital wear and identify the user as either unhealthy or wary of those they are sharing the environment with. For many people wearing a facemask transmits an anti-social feeling that inhibits regular usage.

Various relevant breath mask configurations and constructions have been proposed in the prior art.

U.S. Pat. No. 6,397,395, issued Jun. 4, 2002 to DeHart, discloses a hooded garment having an integral, storable mask or goggles for use to protect the wearer against inclement weather, and particularly for use in outdoor cold weather sports, such as skiing or snowboarding. The mask has the shape of a filled-in, upside-down U. The edges of the U-shaped mask, with the exception of one to two inches on either end of the U is attached to the hood, preferably sewn. The mask attachment is preferably recessed from the hood opening but has the shape of the hood opening.

When wearing this garment, the wearer has the option of wearing the mask or storing the mask flush against the inside, back of the hood. Further, the mask is versatile enough to keep as much or as little of the head, face, and neck of the wearer covered, as the wearer desires. The hood and mask can be adjusted to fit loosely or tight.

In an alternate embodiment, the mask comprises a horizontal separation, which runs across the middle of the mask. The horizontal separation allows the wearer to wear only the upper half of the mask over the eyes and nose of the wearer, to wear only the bottom half of the mask over the mouth of the wearer, or to wear both halves of the mask together over their entire face. The hood of the hooded garment and the mask preferably does not include cumbersome, and potentially dangerous, neck straps, Velcro, or too many drawstrings.

This mask is directed solely to keeping a wearer warm and protected in inclement weather and has no breath filtration capability, as breathing occurs through an unfiltered opening in front of the mouth of the wearer.

Published US Patent Application No. 2011/0107492, published May 12, 2011 to Hinchey et al., discloses an article of protective clothing including a garment for covering at least an upper portion of the body of a wearer; the garment including: a mask element coupled to the garment wherein the mask element can adopt a stowed position and a deployed position in which the mask element extends forward to cover the nose and/or mouth of the wearer. The mask is stowed under a collar at the back of a wearer's garment and is pulled forward over the wearer's head to be moved into a use position over the wearer's nose and mouth.

A shortcoming of this invention is that the entire mask is formed of the filtration material, which is expensive, wasteful of such material, and uncomfortable since only the portion through which the wearer breathes is actually used. Further, in use the mask is not adequately secured in position over the user's face. Because this mask must be pulled forward over the wearer's head it requires that the user must remove any head covering or head gear such as a helmet. In the deployed positon, this mask looks like a typical mask so that the filtration system is very conspicuous to anyone the wearer encounters, which in turn results in stigmatizing both the wearer (as discussed above), as well as people in visual contact with the wearer. This application was abandoned on Feb. 20, 2013, for failure to respond to a Rejection.

Published US Patent Application No. 2017/0055597 A1, published Mar. 2, 2017 to Levken discloses an article of clothing to protect the wearer against airborne contaminants including, but not limited to allergens, bacteria, mold, and viruses such as H1N1 and avian flu. The garment incorporates a HEPA (high efficiency particulate air) filter or enhanced HEPA filter, where such enhancements may include but are not limited to improved anti-microbial properties such as a copper filter that reduces or eliminates the MRSA virus. The garment may be, but is not limited to, a sweatshirt (“hoodie”), jacket, shirt, blouse, scarf, vest, athletic wear, or hooded cap crafted of any fabric. The HEPA filter may be a permanently installed washable filter or a removable replaceable filter or incorporate portions of both. The HEPA filter is placed such that it covers the wearer's nose and mouth; such placement may optionally require the wearer to make attachments.

A shortcoming of this invention is the incorporation of a HEPA facemask filter into the design of a hoodie garment. Other examples of exemplary garments, such as a sweater, bib, or dickie, and especially a turtleneck sweater, are neither illustrated nor discussed and it is not obvious how the HEPA filter would be incorporated into these garments. Contrary to the application's assertion that “the hoodie garment creates a socially acceptable means of wearing a HEPA facemask to protect the wearer from environmental factors including allergens, bacteria, and viruses”, in various societies hoodie garments are perceived as socially undesirable or threatening. Further, a hoodie garment is not a garment of choice in warm-weather climates as the entire head and torso is covered and thus insulated against cooling. Still further, this invention fails to provide a sealed fit that restricts the flow of air in and out as the user breathes through the mask portion while in use.

Finally, since the garment simply incorporates what looks like a standard HEPA (high efficiency particulate air) filter into a hood, the filtration system is very conspicuous to anyone the wearer encounters, which in turn results in stigmatizing both the wearer (as discussed above), as well as people in visual contact with the wearer.

This application was abandoned on Nov. 14, 2017 after a Rejection in view of the above-referenced DeHart patent.

U.S. Pat. No. 9,901,128 B2 issued Feb. 27, 2018 to Gray et discloses a mask apparel of material having a structure that, when repositioned on the wearer, will retain a position about a mouth and nose of the wearer. The fabric has a coating on at least the outer surface and through at least 25% of the fabric of a moisture-sensitive anti-microbial composition and a hydrophilic carrier able to absorb moisture from the exhaled breath of a wearer so as to maintain a wet surface on the carrier to which viral particles will adhere more strongly than to a dry surface of the same carrier.

There are several shortcomings of such garment. One is that the garment itself is the filter and must be cleaned by washing the entire garment. This need to clean is accentuated because the filtration is achieved by viral particles adhering to the surface of the filter. One of the shortcomings of surgical masks is the need to replace them on a regular basis. A mask such as Gray that captures microbes by adherence to its surface will likely have an even shorter use-life between washings.

Another issue with this garment is that the filtration portion of the garment is sticky and uncomfortable for the wearer. Still another set back for that invention is that the filtration portion of the garment has a specified life and when that is finished so is the garment's utility as a filter. And still a further issue with that garment is that the filtration system is very conspicuous to anyone the wearer encounters, which results in stigmatizing both the wearer (as discussed above), as well as people in visual contact with the wearer.

Another shortcoming is that the filtration system is only effective against microscopic microbes that will adhere but not congeal or otherwise block and be visible on the surface of the filter. For airborne contaminants, irritants and dust the Gray filtration is not efficacious and by capturing the particles on its surface will quickly become clogged and inhibit breathing, not to mention look menacing and unattractive.

In addition, the Gray filter is not designed for use by an active user such as an athlete or even a construction worker whose actions will dislodge the garment from its position about the mouth and lose of its wearer. It should also be noted that the Grey filter is not approved by an accepted testing agency nor are universally accepted and published tests available to test the Grey filter for compliance. Because the Grey filter needs moisture to work its efficacy would likely be compromised in dry climates and condition.

Finally, the Grey filter is a fixed falter that is designed to filter only certain types of microbes or particles. It does not permit the user to change the type or characteristics of the filtration to suit the circumstances.

What is needed in the art is a garment affording a high level of convenient filter protection to a wearer, capable of easy handling, with a long life, which provides inconspicuous protection. Such a garment preferably contains a conveniently removable/replaceable element of N95 or other filtration material that is positioned over and covers a wearer's mouth and nose when the garment is unfurled from a non-filtering configuration.

SUMMARY OF THE INVENTION

Briefly described, an exemplary garment in accordance with the present invention comprises a bodice portion, that may include armholes, like a bib or dickey, or sleeves to control rotational positioning on the body and face of a wearer, and an elongated neck portion defining a turtleneck. In common usage, a turtleneck collar is a high collar that covers most of the neck even when the collar is folded over itself. In a first configuration mode, disposed within the front of the turtleneck collar is a replaceable filtration element positioned such that when the collar is unrolled upward into a second configuration mode the filtration element is positioned over the mouth and nose of the wearer who thus breathes through the collar and filtration element. When filtration is no longer needed, the collar may be returned to the first configuration mode.

In one preferred embodiment, a draw-cord is disposed within the end of the turtleneck to permit tight closure of the collar end around the face and ears of the wearer to secure the turtleneck and filtration element in place and prevent leakage.

Alternatively, slots may be formed in the turtleneck to permit the wearer's ears to retain the turtleneck in place. In still another alternative the turtleneck will incorporate a deformable nose bridge that assists the wearer in forming a breath seal of the filter against the wearer's face.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. is a front elevational view of an exemplary garment in accordance with the present invention, shown in a furled mode for normal wearing;

FIG. 2 is a front elevational view of the exemplary garment shown in FIG. 1, shown in an unfurled mode for use as a mask for breathing by a wearer;

FIG. 3 is a is a rear elevational view of the garment shown in FIG. 2; and

FIG. 4 is a plan view of an exemplary filter element for use in the exemplary garment shown in FIGS. 1 through 3.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate currently preferred embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1 through 3, an exemplary garment 10 in accordance with the present invention is shown as a shirt, bib, dickey, or sweater for wearing by a human user. Garment 10 comprises a bodice 12 having first and second armholes 14 and an elongated collar 16. The collar, which is longer than a traditional turtleneck is preferably about 8 to 10 inches in length for adult users and 6-8 inches for children. The collar 16 may be folded downwards over itself at fold line 18 to form a turtleneck collar in known fashion.

Garment 10 may also include sleeves 20 extending outward from armholes 14 in known fashion. Preferably, at least a portion of garment 16 is woven as a knitted fabric. The fabric of garment 10 must permit passage of a wearer's inhaled and exhaled breath therethrough.

At least the portion 22 of elongated collar 16 between fold line 18 and collar cuff 24 is formed in two layers (not shown), permitting placement of a pouch 26 therebetween. Pouch 26 is positioned within portion 22 such that when portion 22 is unfurled along fold line 18 pouch 26 becomes positioned over the mouth and nose of a wearer of garment 10.

In one embodiment of the present invention a draw-cord 28 having a releasable clasp 30 is disposed within collar cuff 24 to permit a wearer to cinch collar cuff 24 snugly against the wearer's head. In another embodiment of the present invention, a deformable nose bridge insert 31 also is disposed within and transversely of portion 22 and adjacent to pouch 26 to assist the wearer in forming a breath seal of portion 22 against the wearer's face. In still another preferred embodiment, slots or loops may be formed in the elongated collar to receive the wearer's ears to assist retention of the turtleneck in place.

Referring now to FIGS. 2 and 4, portion 22 further comprises a slit 32 in one of the two layers of portion 22 providing access to pouch 26 for insertion of an element of medical filtration material 34, e.g., PM2.5, N95, or N99, thus defining garment 10, when unfurled as shown in FIGS. 2 and 3, as a surgical mask.

Filter element 34 must be large enough to cover completely the mouth and nose of a wearer. An exemplary element 34 is shown in FIG. 4 having at least a central width 36 of about 2.8 inches (7 cm), an end width 38 of about 2.4 inches (6 cm), and an overall length 40 of about 4.0 inches (10 cm).

While the invention has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention is not limited to the described embodiments but will have full scope defined by the language of the following claims. 

What is claimed is:
 1. A garment formed of a fabric that permits passage of inhaled and exhaled breath therethrough, comprising: a) a portion of said garment optionally configurable between a first mode wherein said portion is folded away from the mouth and nose of a wearer of said garment and a second mode wherein said portion is disposed over the mouth and nose of a wearer of said garment; and b) an element of a medical filtration material disposed within said portion such that said element is positioned in the pathway of said inhaled and exhaled breath when said garment is in said second mode.
 2. A garment in accordance with claim 1 wherein said garment is in the form of a turtleneck garment having a turtleneck collar wherein said portion is part of said turtleneck collar and is folded over the remainder of said turtleneck collar when said garment is in said first mode and is unfolded from said remainder of said turtleneck collar when said garment is in said second mode.
 3. A garment in accordance with claim 1 wherein said element of medical filtration material is selected from the group consisting of PM2.5, N95, and N99.
 4. A garment in accordance with claim 1 further comprising a pouch disposed within said portion for receiving and removably retaining said element of medical filtration material.
 5. A garment in accordance with claim 1 further comprising a deformable nose bridge insert disposed in said portion.
 6. A garment in accordance with claim 1 further comprising a drawcord and releasable catch disposed within said portion.
 7. A garment in accordance with claim 1 wherein said garment type is selected from the group consisting of shirt, bib, dickey, and sweater.
 8. A garment in accordance with claim 1 wherein said fabric is formed by knitting.
 9. A garment in accordance with claim 2 further comprising a bodice attached to said turtleneck collar.
 10. A method for forming a respiratory mask, comprising the steps of: a) providing a garment formed of a fabric that permits passage of inhaled and exhaled breath therethrough, a portion of said garment being optionally configurable between a first mode wherein said portion is folded away from the mouth and nose of a wearer of said garment and a second mode wherein said portion is disposed over the mouth and nose of a wearer of said garment, said garment further including an element of a medical filtration material disposed within said portion such that said element is positioned in the pathway of said inhaled and exhaled breath when said garment is in said second mode; and b) unfolding said portion from said first mode to said second mode.
 11. A method in accordance with claim 10 wherein said garment is in the form of a turtleneck garment having a turtleneck collar wherein said portion is part of said turtleneck collar and is folded over the remainder of said turtleneck collar when said garment is in said first mode and is unfolded from said remainder of said turtleneck collar when said garment is in said second mode. 